Fittings with redundant seals for aircraft fuel lines, fuel tanks, and other systems

ABSTRACT

Fittings with redundant seals for aircraft fuel lines, fuel tanks, and other systems are disclosed. A fitting in accordance with one embodiment can be positioned adjacent to an aperture in a fuel tank wall having an inner surface and an outer surface. The fitting can include a first member having a flange and a barrel. The barrel can further include a passageway. A first flange seal can be positioned at a face of the flange and can be sealably coupled to a surface, for example, the tank wall. A second flange seal can be disposed outwardly from the first flange seal against the surface. The fitting can further include a second member (e.g., a sensor) positioned within the passageway of the barrel. The fitting can further include first and second barrel seals positioned between the barrel and the second member.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Application60/689,224, filed Jun. 9, 2005 and incorporated herein by reference.

TECHNICAL FIELD

The present invention is directed generally toward fittings withredundant seals for aircraft fuel lines, fuel tanks and other systems.Aspects of the invention are also directed to associated methods.

BACKGROUND

Modern aircraft include complex fuel systems that route aviation fuelfrom fuel tanks to aircraft systems that use the fuel. These aircraftsystems can include the primary engines, and/or auxiliary power units(APUs). In the case of an aerial refueling tanker, these systems canalso include fuel lines, manifolds, and associated valving necessary fordelivering fuel to a receiver aircraft. In some cases, the fuel linesmay pass through “ignition zones,” which are typically pressurizedcompartments in the aircraft (e.g., baggage compartments) that may alsohouse electrical devices. Federal Aviation (FAA) regulations requirethat fuel lines in such areas have redundant seals. However, manyexisting fuel system devices (e.g., sensors) do not include such acapability. Furthermore, servicing such devices during the course ofroutine maintenance procedures can be cumbersome. Accordingly, there isa need in the industry for fuel line components that include redundantseals and are easily serviceable.

SUMMARY

The following summary is provided for the benefit of the reader only,and is not intended to limit in any way the invention as set forth bythe claims. The present invention is directed generally to fluidfittings and associated systems and methods. A fluid fitting inaccordance with one aspect of the invention includes a first memberhaving a flange and a barrel, the barrel having a passageway. A firstflange seal can be positioned at a face of the flange so as to sealablycouple to a surface. A second flange seal can be positioned at theflange face and can be disposed outwardly from the first flange seal tosealably couple to the surface. The fitting can further include a secondmember positioned within the passageway of the barrel. First and secondbarrel seals positioned between the barrel and the second member canseal the interface between the first and second members. Accordingly,the fitting can provide for redundantly sealed, fluid-tight connections.

In further particular embodiments, a fitting having characteristicsgenerally similar to those described above can be attached to a fueltank having a tank wall with an inner surface, an outer surface, and anaperture extending from the inner surface to the outer surface. A firstportion of the barrel can extend through the tank aperture and can besecured to the tank wall with a fastener. A second portion of the barrelcan extend away from the tank aperture. The second member can bepositioned within the passageway of the barrel, and in at least someinstances, can include a sensor, for example, a pressure sensor.

Still further aspects of the invention are directed to methods forinstalling a fluid fitting. A method in accordance with one aspect ofthe invention includes coupling a first member of a fitting proximate toan aperture in a wall. The wall can separate a first region from asecond region, with the aperture extending through the wall from thefirst region to the second region. The method can further includesecuring the first member relative to the wall, and placing a flange ofthe first member proximate to the wall in the second region, with afirst flange seal and a second flange seal positioned between the flangeand the wall. The method can further include inserting a second memberof the fitting into a passageway of the barrel, with the passageway influid communication with the first region. The method can still furtherinclude sealing an interface between the second member and thepassageway with a first barrel seal and a second barrel seal. In furtherparticular aspects of the invention, the second member of the fittingcan be removed from the passageway without accessing the first region.Accordingly, the fitting can include a redundant sealing capability, andcan be easily serviced without accessing both sides of the wall to whichthe fitting is attached.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially schematic, isometric illustration of an aircrafthaving a fuel system that includes fittings configured in accordancewith an embodiment of the invention.

FIG. 2 is a partially schematic, exploded view of a fitting configuredin accordance with an embodiment of the invention.

FIGS. 3A and 3B illustrate an external side view and a cross-sectionalside view, respectively, of a fitting assembled in accordance with anembodiment of the invention.

FIGS. 4A and 4B illustrate an external side view and a cross-sectionalside view, respectively, of a second member of a fitting configured inaccordance with an embodiment of the invention.

FIG. 5 illustrates a cross-sectional side view of a fitting thatincludes a sensor configured in accordance with another embodiment ofthe invention.

FIGS. 6A and 6B are partially schematic, cross-sectional illustrationsof fittings that include sensors coupled to shrouded conduits inaccordance with further embodiments of the invention.

FIG. 7 is a flow diagram illustrating a method for installing a fittingin accordance with still another embodiment of the invention.

DETAILED DESCRIPTION

The present disclosure describes fittings with redundant seals for usein aircraft fuel lines and other systems, and also discloses associatedmethods. Certain specific details are set forth in the followingdescription and in FIGS. 1-7 to provide a thorough understanding ofvarious embodiments of the invention. Well-known structures, systems andmethods often associated with such systems have not been shown ordescribed in detail to avoid unnecessarily obscuring the description ofthe various embodiments of the invention. In addition, those of ordinaryskill in the relevant art will understand that additional embodiments ofthe invention may be practiced without several of the details describedbelow.

FIG. 1 illustrates an aircraft 100 (e.g., a refueling aircraft) in theprocess of refueling a receiver aircraft 120. The aircraft 100 caninclude a fuselage 101, wings 102, and one or more engines 103 (two areshown in FIG. 1 as being carried by the wings 102). In otherembodiments, the aircraft 100 can have other configurations, and in atleast some embodiments, need not include a refueling capability. In aparticular aspect of the embodiment shown in FIG. 1, the aircraft 100includes a fuel system 110 having wing-mounted fuel tanks 111 (and/orother fuel tanks) and fuel lines 160 that provide fuel to other aircraftsystems. These systems can include the engines 103, an auxiliary powerunit (APU) 105, and an aerial refueling system 113. The fuel lines 160may pass through pressurized compartments 104. In at least someinstances, the fuel system 110 includes devices (e.g., sensors) thatrequire access through a tank wall 114 of the fuel tanks 111. Aspects ofthe invention are directed to fittings that support such an installation(and others as well), and that include redundant seals, as described ingreater detail below with reference to FIGS. 2-7.

FIG. 2 is a partially schematic, exploded illustration of a fitting 130that can be coupled to the tank wall 114 or another structure inaccordance with an embodiment of the invention. The tank wall 114 caninclude oppositely facing first and second surfaces 115 a, 115 b, andcan separate a first region 116 a from a second region 116 b. The firstregion 116 a can include a region internal to a fuel tank 111, and thesecond region 116 b can include a region external to the fuel tank 111.The tank wall 114 can include an aperture 117 that extends from thefirst surface 115 a to the second surface 115 b and allows for fluidcommunication with the first region 116 a.

A fitting 130 can provide a redundantly sealed connection between theaperture 117 and other systems or devices that require access to thefirst region 116 a. Such devices can include sensors 150 (e.g., pressuresensors or temperature sensors), bleed valves, or other externaldevices. In some cases, both the external device and an associatedaccess point within the fuel tank 111 are remote from the aperture 117.In such instances, the fitting 130 can be coupled to a first conduit 140a that extends into the interior of the fuel tank 111, and a secondconduit 140 b that extends away from the fuel tank 111 in the secondregion 116 b. In other embodiments, either or both of these conduits 140a, 140 b may be eliminated.

In any of the foregoing embodiments, the fitting 130 can include a firstmember 131 sealably connected to the tank wall 114, and a second member132 sealably connected to the first member 131. Accordingly, the firstmember 131 can include a barrel 134 having a first portion 135 a thatextends into the first region 116 a, and a second portion 135 b thatextends into the second region 116 b. The barrel 134 can include a firstpassageway 136 that provides for fluid communication with the firstregion 116 a. The first portion 135 a can be threaded so as to besecured to the tank wall 114 with a fastener 144 (e.g., a nut) and anoptional washer 145.

The first member 131 can also include a flange 133 that faces toward thesecond surface 115 b of the tank wall 114. Two flange seals 137 (shownas a first flange seal 137 a and a second flange seal 137 b) sealablycouple the flange 133 to the second surface 115 b. Accordingly, the twoflange seals 137 can provide a redundant sealing arrangement between thefirst member 131 and the aperture 117.

The second member 132 can extend at least partially into the firstpassageway 136 of the first member 131. The second member 132 caninclude two barrel seals 139 (shown as a first barrel seal 139 a and asecond barrel seal 139 b) that seal the interface between the secondmember 132 and the first member 131. The second member 132 can alsoinclude an internal second passageway 138 that is in fluid communicationwith the first passageway 136.

FIGS. 3A and 3B illustrate an external side view and a sidecross-sectional view, respectively, of the fitting 130 in its assembledstate. Referring first to FIG. 3A, the second member 132 is received inthe first member 131. The first conduit 140 a can be attached to thefirst member 131 with a first coupling 141 a and the second conduit 140b can be attached to the second member 132 with a second coupling 141 b.The first and second conduits 140 a, 140 b can be shrouded (e.g.,double-walled) or unshrouded.

Referring next to FIG. 3B, the first member 131 can be securely engagedwith the tank wall 114 by tightening the fastener 144 until the firstand second flange seals 137 a, 137 b provide a fluid-tight seal betweenthe flange 133 and the second surface 115 b of the tank wall 114. Thesecond member 132 can be inserted into the first passageway 136 andconnected to the first member 131 by engaging external threads 147 a ofthe second member 132 with internal threads 147 b of the first member131. The first and second barrel seals 139 a, 139 b seal the interfacebetween the second member 132 and the internal surfaces of the firstpassageway 136. Further details of the barrel seals 139 a, 139 b aredescribed below with reference to FIGS. 4A and 4B.

FIGS. 4A and 4B illustrate an external side view and a sidecross-sectional view, respectively, of the second member 132. The firstand second barrel seals 139 a, 139 b can provide for a redundantlysealed connection with the first member 131 (FIG. 3B). The first barrelseal 139 a can include an O-ring positioned between the external threads147 a and a seat 146. Accordingly, the first barrel seal 139 a can becaptive and will be unlikely to move when the second member 132 isinstalled or removed. The second barrel seal 139 b can be positioned ina seal groove 148 and can include an O-ring 142 positioned between twobackup rings 143. The backup rings 143 can prevent or at least restrictthe O-ring 142 from moving out of the seal groove 148 when the secondmember 132 is installed and/or removed.

In an embodiment described above with reference to FIG. 2, the fitting130 can provide a connection to a remote sensor 150. In otherembodiments, the sensor can be integrated with the second member 132,and the second conduit 140 b shown in FIG. 2 can be eliminated. Forexample, referring now to FIG. 5, a fitting 530 configured in accordancewith another embodiment of the invention includes a first member 131generally similar to the first member 131 described above with referenceto FIGS. 2-3B, and a second member 532 that includes an integratedsensor 550. The sensor 550 can include a pressure transducer,temperature sensor or other sensor. Suitable sensors are available fromKulite Semiconductor Products, Inc., of Leonia, N.J. Other aspects ofthe second member 532 (e.g., the first and second barrel seals 139 a,139 b) and the threaded attachment with the first member 131 can begenerally similar to those described above.

In still further embodiments, the fitting 530 can have otherconfigurations. For example, the fitting 530 can combine aspects of thearrangement shown in FIG. 2 with aspects of the arrangement shown inFIG. 5. In particular, the fitting 530 can include an integral sensor550, but can also include the capability for coupling to a secondconduit 140 b (FIG. 2) that can in turn be coupled to additional remotesensors or can be used for other purposes. Accordingly, the fitting 530can include second member 532 having a through-passage generally similarto the second passageway 138.

FIG. 6A illustrates a fitting 630 a coupled to a conduit 660 (e.g., afuel line) in accordance with another embodiment of the invention. Theconduit 660 can have a shrouded arrangement and can accordingly includean inner conduit 661 with an outer conduit 662 disposed annularlyoutwardly from the inner conduit 661. The outer conduit 662 can beprovided to capture fluid that may inadvertently leak from the innerconduit 661.

In at least one aspect of an embodiment shown in FIG. 6A, the fitting630 a can include a sensor 550 configured to detect leaks from the innerconduit 661 to the outer conduit 662. Accordingly, the outer conduit 662can include an aperture 617 a through which evidence of such a leak maybe communicated. The fitting 630 a can include a first member 631 a thatis integrally connected or attached to the outer conduit 662 around theaperture 617 a. Accordingly, the first member 631 a need not includeredundant flange seals such as those described above with reference toFIGS. 2-3B. The first member 631 a can be attached to a second member532 that is generally similar to the second member 532 described abovewith reference to FIG. 5. Accordingly, the second member 532 can includean integral sensor 550 having a barrel portion, along with first andsecond barrel seals 139 a, 139 b that seal an interface with acorresponding first passageway 636 in the first member 631. In anotherembodiment, the second member 532 with its integral sensor 550 can bereplaced with a second member 132 generally similar to that describedabove with reference to FIGS. 2-4B to allow coupling to a remote sensoror other device.

FIG. 6B is a partially cut away, isometric illustration of a fitting 630b connected to the conduit 660 in accordance with another embodiment ofthe invention. In one aspect of this embodiment, the fitting 630 bprovides fluid communication with the inner conduit 661, but not theouter conduit 662. Accordingly, the inner conduit 661 can include anaperture 617 b. A channel housing 670 having a channel 671 can becoupled to the conduit 660 so that the channel 671 is in fluidcommunication with the aperture 617 b, but is isolated from fluidcommunication with the outer conduit 662. The fitting 630 b can includea first member 631 b that attaches to the channel housing 670.Accordingly, the first member 631 b can include a barrel 634 having afirst passageway 636 that is aligned with the channel 671 and thechannel housing 670. The first member 631 b can further include a flange633 positioned against the channel housing 670. First and second flangeseals 637 a, 637 b provide a redundant seal arrangement between thechannel 671 and the first passageway 636. The fitting 630 b can alsoinclude a second member 532 generally similar to that described above.The second member 532 can connect with the first member 631 b in amanner generally similar to that described above, and can include anintegrated sensor 550. In other embodiments, the second member 532 caninclude a through-passage generally similar to that shown in FIG. 2, inaddition to or in lieu of the integrated sensor 550. In either of theseembodiments, the second member 532 can include redundant first andsecond barrel seals 139 a, 139 b that provide a sealable connectionbetween the second member 532 and the first member 631 b.

FIG. 7 is flow diagram illustrating a process 700 for installing and,optionally, removing a fitting in accordance with an embodiment of theinvention. The process 700 can include coupling a first member of afitting proximate to an aperture in a wall (process portion 702). Thewall can separate a first region from a second region, and the aperturecan extend through the wall from the first region to the second region.In a particular embodiment, process portion 702 can also includeinserting a barrel portion of the first member into the aperture. Theprocess can further include securing the first member relative to thewall (process portion 704). In a particular embodiment, process portion704 can include fastening the first member from the first region. Inother embodiments, the first member can be fastened from the secondregion.

In process portion 706, the process can include sealing a flange of thefirst member against the wall in the second region, with a first flangeseal and a second flange seal. The first and second flange seals can bepositioned annularly with respect to each other, for example, asdescribed above with reference to FIG. 2. The process 700 can stillfurther include inserting a second member of the fitting into apassageway of the first member, with the passageway being in fluidcommunication with the first region (process portion 708). An interfacebetween the second member and the passageway can be sealed with a firstbarrel seal and a second barrel seal (process portion 710). For example,this interface can be sealed with two barrel seals that are axiallydisposed with respect to each other, as described above with referenceto FIG. 2.

In a particular aspect of an embodiment shown in FIG. 7, the process canfurther include removing the second member of the fitting from thepassageway without accessing the first region (process portion 712). Forexample, referring to FIG. 3B, the second member 132 can be threadablyseparated from the first member 131 by accessing the second region 116b, and without accessing the first region 116 a. In particular, a userremoving the second member 132 need not remove the first member 131 andneed not access the fastener 144 that secures the first member 131 tothe tank wall 114.

One feature of at least some embodiments of the fittings described abovewith reference to FIGS. 1-7 is that they can include redundant seals.For example, the first second flange seals can be located at differentpoints along a radially extending potential leak path that passesbetween the flange and the surface it abuts. If one of the flange sealsfails, the other can still prevent leakage along the leak path. In agenerally similar manner, the first and second barrel seals can belocated along an axially extending potential leak path extending alongthe inner surface of the barrel, and if either barrel seal fails, theother can prevent leakage along this path. An advantage of this featureis that it allows certain structures (e.g., fuel tanks) to be penetratedwhile preserving compliance with requirements for redundant seals. Inparticular embodiments, this arrangement can allow sensors to haveaccess to the interior of fuel tanks, without compromising a requirementfor redundant seals in an external area (e.g., a pressurized compartment104) outside the fuel tank. The redundant seals can be fluid-tight(e.g., liquid-tight and/or gas-tight).

Another feature of at least some embodiments of the fittings describedabove with reference to FIGS. 1-7 is that they can be installed andremoved with common hand tools. For example, the connections between thefirst and second members described above can be threaded connectionsthat can be secured and released with wrenches or other suitable handtools. An advantage of this arrangement is that it can reduce the timeand expense associated with installing and removing such devices.

Still another feature of at least some embodiments of the fittingsdescribed above with reference to FIGS. 1-7 is that the seals can bepositioned so as to reduce or eliminate the likelihood for damage to theseals during installation or removal. For example, the flange seals 137a, 137 b can be installed and removed without having the seals “roll” orotherwise rub against surfaces that might cause the seals to becomedisplaced. The first barrel seal 139 a can be located against a seat 146to prevent it from rolling during installation or removal. The secondbarrel seal 139 b can be held captive in a seal groove 148 and can befurther secured with back up rings 143 to prevent it from rolling out ofposition during installation and/or removal.

Still another feature of at least some embodiments of the fittingdescribed above with reference to FIGS. 1-7 is that part of the fittingcan be removed without necessarily removing the entire fitting, andwithout requiring access to both sides of the tank wall 114 or otherstructure in which the fitting is positioned. For example, the secondmember 132 can be removed without requiring removal of the first member131. Furthermore, the second member 132 can be removed by accessing thesecond region 116 b, and without accessing the first region 116 a.

From the foregoing, it will be appreciated that specific embodiments ofthe invention have been described herein for purposes of illustration,but that various modifications may be made without deviating from theinvention. For example, the first and second members described above canhave different arrangements, while still providing redundant seals. Thefittings can be attached to structures other than fuel tanks andshrouded conduits, and can handle fluids other than fuel. The fittingsmay be used in aircraft other than tanker aircraft, and/or innon-aircraft installations. Aspects of the invention described in thecontext of particular embodiments may be combined or eliminated in otherembodiments. For example, the fittings can be used with both integralsensors and remote sensors, or without sensors. Further, whileadvantages associated with certain embodiments of the invention havebeen described in the context of those embodiments, other embodimentsmay also exhibit such advantages, and not all embodiments neednecessarily exhibit such advantages to fall within the scope of theinvention. Accordingly, the invention is not limited, except as by theappended claims.

1-6. (canceled)
 7. A fluid fitting arrangement, comprising a firstmember having a flange with a flange face, and a barrel with apassageway; a first flange seal at the flange face, the first flangeseal being positioned to sealably couple to a surface; a second flangeseal at the face of the flange, the second flange seal being disposedoutwardly from the first flange seal and being positioned to sealablycouple to the surface; a second member positioned within the passagewayof the barrel; a first barrel seal positioned between the barrel andsecond member; and a second barrel seal positioned between the barreland the second member.
 8. The arrangement of claim 7 wherein a potentialleak path is located between the first member and the second member andwherein the first barrel seal is positioned at a first location alongthe potential leak path, with the second barrel seal positioned at asecond location along the potential leak path, the second location beingspaced apart from the first location, the second seal providing aredundant seal in the event of a failure of the first seal.
 9. Thearrangement of claim 7 wherein the surface includes the surface of afuel tank, and wherein the fuel tank has an aperture, and wherein thefirst and second flange seals are positioned around the aperture. 10.The arrangement of claim 7, further comprising a fuel line having anaperture generally transverse to a flow axis of the fuel line, andwherein the first and second flange seals are positioned around theaperture.
 11. The arrangement of claim 10 wherein fuel line includes aninner conduit positioned annularly within an outer conduit, and whereinthe passageway of the barrel is in fluid communication with the innerconduit but not the outer conduit.
 12. The arrangement of claim 10wherein fuel line includes an inner conduit positioned annularly withinan outer conduit, and wherein the passageway of the barrel in fluidcommunication with the outer conduit but not the inner conduit.
 13. Thearrangement of claim 7 wherein the second member positioned within thepassageway of the barrel includes a sensor.
 14. The arrangement of claim7, further comprising: a fuel tank having a wall with an inner surfaceadjacent to an inner region, an outer surface adjacent to an outerregion, and an aperture extending from the inner surface to the outersurface, wherein the barrel extends through the aperture and wherein thefirst and second flange seals seal against the outer surface; and afastener connecting the barrel to the wall, the fastener beingaccessible from the inner region of the fuel tank, but not the outerregion, and wherein the second member includes a pressure sensoraccessible from the outer region of the fuel tank but not the innerregion, the second member being removable from the first member from theouter region of the fuel tank, but not from the inner region.
 15. Thefitting of example 7 wherein the first and second flange seals includeO-rings disposed annularly relative to each other.
 16. The fitting ofexample 7 wherein the first and second barrel seals include O-ringsdisposed axially relative to each other.
 17. A method for installing afluid fitting, comprising: coupling a first member of a fluid fittingproximate to an aperture in a wall, the wall separating a first regionfrom a second region, with the aperture extending through the wall fromthe first region to the second region; securing the first memberrelative to the wall; placing a flange of the first member proximate tothe wall in the second region, with a first flange seal and a secondflange seal positioned between the flange and the wall; inserting asecond member of the fitting into a passageway of the first member, thepassageway being in fluid communication with the first region; andsealing an interface between the second member and the passageway with afirst barrel seal and a second barrel seal.
 18. The method of example17, further comprising removing the second member of the fitting fromthe passageway without accessing the first region.
 19. The method ofclaim 17 wherein: the wall includes a wall of a fuel tank, with thefirst region being within the fuel tank and the second region beingexternal to the fuel tank; securing the first member includes securingthe first member from a position within the fuel tank; sealing a flangeincludes sealing the flange with a first O-ring seal and a second O-ringseal positioned annularly outwardly from the first O-ring seal;inserting a second member includes inserting a second member thatincludes a pressure sensor; sealing an interface between the secondmember and the passageway includes sealing the interface with a thirdO-ring and a fourth O-ring spaced axially apart from the third O-ringalong the passageway.
 20. The method of claim 17 wherein coupling thefirst member includes coupling the first member to a fuel tank.
 21. Themethod of claim 17 wherein coupling the first member includes couplingthe first member to a fuel line.
 22. The method of claim 17 whereincoupling the first member includes coupling the first member to a fuelline having an inner conduit and an outer conduit disposed annularlyaround the inner conduit, with the passageway being in fluidcommunication with the inner conduit but not the outer conduit.
 23. Themethod of claim 17 wherein coupling the first member includes couplingthe first member to a fuel line having an inner conduit and an outerconduit disposed annularly around the inner conduit, with the passagewaybeing in fluid communication with the outer conduit but not the innerconduit.
 24. The method of claim 17, further comprising sealing aninterface between the flange and the wall with the first flange sealuntil the first flange seal fails, and sealing the interface between theflange and the wall with the second flange seal after the first flangeseal fails.
 25. The method of claim 17, further comprising sealing theinterface between the second member and the passageway with the firstbarrel seal until the first barrel seal fails, and sealing the interfacebetween the second member and the passageway with the second barrel sealafter the first barrel seal fails.